Patent Application
20080118332
This claimed technology relates generally to screw type fasteners and, more particularly, to a drywall screw that generates a gap between structural member and drywall to produce sound insulation.
Gypsum board (commonly referred to as “drywall”) is a common artificial building material used globally for the construction of interior walls and ceilings. Drywall is made primarily from gypsum plaster, the semi-hydrous form of calcium sulphate (CaSO4.½H2O). The plaster is mixed with fiber (typically paper and/or fiberglass), foaming agent, various additives that increase mildew and fire resistance, and water, and is then formed by sandwiching a core of wet gypsum between two sheets of heavy paper or fiberglass mats. When the core sets and is dried, the sandwich becomes rigid and strong enough for use as a building material.
Drywall is typically available in 4 ft. (approx. 1200 mm) wide sheets of various lengths. Newly formed sheets are cut from a belt, the result of a continuous manufacturing process. In some commercial applications, sheets up to 16 ft. are used. Larger sheets make for faster installation, since they reduce the number of joints that must be finished. Often, a sizable quantity of any custom length may be ordered, from factories, to exactly fit ceiling-to-floor on a large project. The most commonly used drywall is about ½ in. thick, but can range from ¼ in. (6.35 mm) to 1 in. (25 mm).
During construction, drywall is cut to size, using a large T-square, by scoring the paper on the front side (usually white) with a utility knife, breaking the sheet along the cut, scoring the paper backing, and finally breaking the sheet in the opposite direction. Small features such as holes for outlets and light switches are usually cut using a keyhole saw or a small high-speed bit in a rotary tool. Drywall is then fixed to the wall structure with nails, or more commonly in recent years, specially designed screws. Drywall screws typically have an acute point, widely spaced threads, and a curved top, allowing them to self-pilot and install rapidly without punching through the paper cover.
Repairs are commonly needed when screws or nails work themselves loose or pop out of a drywall surface. A “pop” is an imperfection that occurs in drywall when the point of attachment of drywall to the wood framing of the house fails. Average pops are usually about the size of a quarter and are either convex or concave, depending upon the cause. Either the drywall moved and the screw stayed still, or the screw moved and the drywall stayed still. Both result in a pop. Sometimes the screw or nail head becomes exposed. Screwing or pounding them back into place usually does not prevent the problem from recurring. As such, substantial drywall repair is required to fix even a minor pop. Current screws available in the marketplace do not fully prevent the likelihood that a pop will occur.
Another common problem with drywall is that it easily transmits noise between rooms. Sound waves hit structural components, like walls, and the sound energy vibrates the wall. The wall, in turn, transmits the energy and creates a new wave on the other side. When a common wall separates two rooms, the sound generated in both rooms carries between them. Drywall, which is fairly flexible, is good at transmitting sound.
Air space serves to dampen sound waves. Sound attenuates, or loses energy, as it travels through the still air, just as the ripple from a rock thrown in a pond will grow smaller and smaller as it radiates outwards through the water. As such, it would be beneficial to leave a gap or space filled with dead air between the drywall and stud (or other framing), thus contributing to sound insulation. The present drywall screw addresses these needs.
The following is not in any way to limit, define or otherwise establish the scope of legal protection. In general terms, the present claimed technology relates to a drywall screw. One object is to provide an improved drywall screw that generates a gap between structural member and drywall to produce sound insulation. Further objects, embodiments, forms, benefits, aspects, features and advantages of the claimed technology may be obtained from the description, drawings and claims provided herein.
For the purposes of promoting an understanding of the principles of the novel technology and presenting its currently understood best mode of operation, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the novel technology is thereby intended, with such alterations and further modifications in the illustrated device and such further applications of the principles of the novel technology as illustrated therein being contemplated as would normally occur to one skilled in the art to which the novel technology relates.
The fastener 10 includes a first threaded section 30 and a second threaded section 40, said first threaded section 30 being closer to said point end 16 than said second threaded section 40. The threads 32 of the first threaded section 30 are characterized by a first pitch 34, and the threads 42 of the second threaded section 40 have a second pitch 44. The first pitch 34 is greater than the second pitch 44. Further, the threads 32 of the first threaded section 30 have a first thread diameter 36, and the threads 42 of the second threaded section 40 have a second thread diameter 46 larger than the first thread diameter 36.
The shank 12 is typically of uniform diameter and is relatively thin compared to the dimensions of the threads 42 of the second threaded section 40, such that drywall dust is compressed between the threads 42 rather than building up and causing drywall pops.
As shown in
Turning now to
Further, the length of the second portion 40 may be matched to the thickness of the drywall 50, such that the fastener 10 automatically sets and stops when the second portion 40 begins to engage the structural member 60, since substantially greater torque is required to drive the wider and larger threads of the second portion 40 through a wood stud (or other such structural materials more dense than drywall).
Another advantage of the present technology is that “popping” of the fastener 10 is minimized, since the fastener 10 tends to grip and pull the drywall 50 outwardly with it instead of popping through as the structure 60 settles.
While the novel technology has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It is understood that the embodiments have been shown and described in the foregoing specification in satisfaction of the best mode and enablement requirements. It is understood that one of ordinary skill in the art could readily make a nigh-infinite number of insubstantial changes and modifications to the above-described embodiments and that it would be impractical to attempt to describe all such embodiment variations in the present specification. Accordingly, it is understood that all changes and modifications that come within the spirit of the novel technology are desired to be protected.
